Download Burnham Series 2B Operating instructions

INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
Series 2® (model B)
Gas - Fired Boiler
9700609
F o r s e r vi c e o r r e p a i r s t o b o i le r, c a ll yo ur he a t i ng c o nt r a c t o r. W he n s e e k i ng i nf o r m a t i o n o n b o i le r,
p r o vi d e B o i l e r M o d e l N u m b e r a n d S e r i a l N u m b e r a s s h o w n o n R a t i n g L a b e l .
B o i l e r M o d e l N um b e r
B o i l e r S e r i a l N um b e r
Ins t a lla ti o n D a te
2
H e a t i ng C o nt r a c t o r
P h o ne N u m b e r
A d d re s s
103385-01 - 1/11
Price - $5.00
NOTE: The equipment shall be installed in accordance with those installation regulations in force in the area where the
installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before
installations are made.
All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.
The New York City Department of Buildings has approved the Series 2B boiler: Approval No. MEA 96-96-E
The City of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved the Series 2B boiler. See the Massachusetts Board of
Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.asp for the latest Approval Code or ask
your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.
Table of Contents
IV. Service...............................................26
I. Installation Instructions.................... 4
II. Operating Instructions......................18
V. Repair Part........................................29
III. Trouble Shooting..............................25
VI. Appendix
Low Water Cut Off............................51
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or
to important information concerning the life of the product.
DANGER
CAUTION
Indicates presence of a hazard which will cause
severe personal injury, death or substantial
property damage if ignored.
Indicates presence of a hazard which will or can
cause minor personal injury or property damage
if ignored.
WARNING
NOTICE
Indicates presence of a hazard which can cause
severe personal injury, death or substantial
property damage if ignored.
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
WARNING
FAILURE TO FOLLOW ALL INSTRUCTIONS IN PROPER ORDER CAN CAUSE PERSONAL INJURY OR
DEATH. READ ALL INSTRUCTIONS BEFORE INSTALLING.
WARNING
SERVICE ON THIS BOILER SHOULD BE UNDERTAKEN ONLY BY TRAINED AND SKILLED PERSONNEL.
KEEP BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER
FLAMMABLE VAPORS AND LIQUIDS.
DO NOT PLACE ANY OBSTRUCTION IN THE BOILER ROOM THAT WILL HINDER THE FLOW OF
COMBUSTION AND VENTILATING AIR.
WARNING
READ THESE INSTRUCTIONS CAREFULLY BEFORE PROCEEDING WITH THE INSTALLATION OF BOILER.
POST INSTRUCTIONS NEAR BOILER FOR REFERENCE BY OWNER AND SERVICE TECHNICIAN. MAINTAIN
INSTRUCTIONS IN LEGIBLE CONDITION.
Dimensions [Inches]
Gas
Approx.
Water Recommended
Connection
Shipping
Content
Vent Size
For Automatic
Weight
[gallons]
[1] [2]
Gas Valve
[lb.]
Boiler
Model
Number
A
B
C
D
E
F
G
202
18-3/4
10-3/4
6-3/8
4
45-5/8
8-1/2
10 [3]
1/2
2.5
3" dia. x 15 ft.
212
202X
20
12
6
4
45-5/8
8-1/2
4-3/4
1/2
3.2
4" dia. x 15 ft.
262
203
20
12
6
4
45-5/8
8-1/2
4-3/4
1/2
3.2
4" dia. x 15 ft.
262
204
23-1/4
15-1/4
7-5/8
5
47-1/8
9-1/8
4-3/4
1/2
4
5" dia. x 15 ft.
306
205
26-1/2
18-1/2
9-1/4
6
48-1/2
9-3/4
5-1/4
1/2
4.7
6" dia. x 15 ft.
354
206
29-3/4
21-3/4
10-7/8
6
48-1/2
9-3/4
5-1/4
1/2
5.5
6" dia. x 15 ft.
414
207
33
25
12-1/2
7
50-1/8
10-3/8
6-5/8
3/4
6.2
7" dia. x 15 ft.
458
208
36-1/4
28-1/4
14-1/8
7
50-1/8
10-3/8
6-5/8
3/4
7
7" dia. x 15 ft.
514
209
39-1/2
31-1/2
15-3/4
8
52
11
7-1/4
3/4
7.7
8" dia. x 15 ft.
550
210
42-3/4
34-3/4
17-3/8
8
52
11
7-1/4
3/4
8.5
8" dia. x 15 ft.
608
[1] 15' chimney height is from bottom of draft hood opening to top of chimney.
[2] Refer to the National Fuel Gas Code for equivalent areas of circular and rectangular flue linings.
Maximum Allowable Working Pressure - 30 PSI (Water Only)
[3] 202 only. Dimension 'G' includes allowance for 4" x 3" reducer furnished with boiler. See Figure 8.
Figure 1
I . Installation Instructions
1. Inspect shipment carefully for any signs of
damage. All equipment is carefully manufactured,
inspected and packed. Our responsibility ceases upon
delivery of Boiler to the carrier in good condition. Any
claims for damage or shortage in shipment must be filed
immediately against the carrier by the consignee. No
claims for variances or shortages will be allowed by
Boiler Manufacturer unless presented within sixty (60)
days after receipt of equipment.
2. Boiler installation must conform to the
requirements of the authority having jurisdiction, or in
the absence of such requirements, to:
U.S.A. National Fuel Gas Code, ANSI Z223.1.
When required by the authority having juris-
diction, the installation must conform to ANSI/ASME No. CSD-1.
Canada - Installation Codes for Natural and LP Gas Burning Appliances and Equipment, CAN/
CSA-B149.1.
3. These Gas Boilers are DESIGN CERTIFIED FOR
installation on combustible flooring.
Do not install these boilers on
carpeting.
NOTICE
Do not drop boiler. Do not bump boiler jacket
against floor.
4. Locate boiler in front of or behind installation
position before removing Crate. Locate on a level floor
as close to chimney as possible. For basement
installations, provide a solid base such as concrete, if
floor is not level or if water may be encountered on
floor around Boiler.
The boiler shall be installed such that the gas ignition
system components are protected from water (dripping,
spraying, rain, etc.) during boiler operation and service
(circulator replacement, control replacement, etc.).
DANGER
Do not install boiler where gasoline or other
flammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals,
sprays, paint removers, fabric softeners, etc.) are
used or stored.
5. Remove crate -
A. Remove all crate fasteners. Lift off outside
container.
B. Remove all screws and brackets securing boiler to
skid.
C. Save two of the wooden slats from the container
sleeve for use in Steps D & E.
D. Tilt the boiler to one side and slide a wooden slat
under the two raised feet.
E. Tilt the boiler to the other side and slide another
wooden slat under the two raised feet.
F. Slide the boiler forward or backward off the skid
using the two wooden slats as runners.
6. Move boiler to permanent position.
7. PROVIDE CLEARANCE and AIR for COMBUSTION and VENTILATION.
WARNING
Adequate combustion and ventilation air must be
provided to assure proper combustion.
A. CLEARANCES
1. ALL INSTALLATIONS - Practical service
clearances must be considered (see Figure 1). A
minimum of 24" (6.0cm) from the left side and
front jacket panels is recommended for servicing
but may be reduced to minimum shown in
Figure 2. Subject to boiler and system piping,
left side clearance may be reduced to 1" (2.5cm)
if right side clearance is increased to 9"
(22.9cm).
2. ALCOVE INSTALLATIONS - An alcove is
considered a closet as shown in Figure 2 less
front. Height clearance may be reduced to 27"
(68.6cm).
3. UNCONFINED SPACE (see definition,
paragraph (B) below) - Height clearance may be
reduced to 27" (68.6cm).
B. PROVIDE COMBUSTION AND VENTILATION
AIR in accordance with applicable provisions of
local building codes, or: U.S.A. - National Fuel
Gas Code, NFPA 54/ANSI Z223.1, Canada Natural and Propane Gas Installation Code, CAN/
CSA-B149.1.
1. CLOSET INSTALLATIONS (confined space) in
a building of other than unusually tight
construction (see definition below), provide
combustion and ventilation air as shown in
Figure 2.
2. Installations other than closet in paragraph (1) :
a. Determine volume of space (boiler room).
Rooms communicating directly with space
(through openings not furnished with doors)
are considered part of space.
Figure 2: Minimum Clearances
Volume [ft³](m3) = Length [ft](m) x Width
[ft](m) x Height [ft](m)
b. Determine Total Input of all appliances in
space. Round result to nearest 1,000 Btu per
hour (Btuh).
c. Determine type of space. Divide Volume by
Total Input.
i. If result is greater than or equal to 50 ft³
(1.4m3) per 1,000 Btuh, space is
considered an unconfined space.
ii. If result is less than 50 ft³ (1.4m3) per
1,000 Btuh, space is considered a confined
space.
d. Determine building type. A building of
unusually tight construction has the
following characteristics:
i. Walls and ceiling exposed to outside
atmosphere have a continuous water vapor
retarder with a rating of 1 perm or less
with openings gasketed and sealed, and
ii. Weather-stripping has been added on
openable windows and doors, and
iii. Caulking or sealants applied in joints
around window and door frames, between
sole plates and floors, between wallceiling joints, between wall panels, at
plumbing and electrical penetrations, and
at other openings.
e. For boiler located in a building of other than
unusually tight construction, adequate
combustion and ventilation air is normally
provided by fresh air infiltration through
cracks around windows and doors.
f. For boiler located in building of unusually
tight construction, provide outdoor air
through two permanent openings which
communicate directly or by duct with the
outdoors or spaces (crawl or attic) freely
communicating with the outdoors. Locate
one opening within 12 inches (30.5cm) of
top of space. Locate remaining opening
within 12 inches (30.5cm) of bottom of
space. Minimum dimension of air opening is
3 inches (7.6cm). Size each opening per
following:
i. Direct communication with outdoors.
Minimum free area of 1 square inch
(6.5cm2) per 4,000 Btu per hour input of
all equipment in space.
ii.Vertical ducts. Minimum free area of 1
square inch (6.5cm2) per 4,000 Btu per
hour input of all equipment in space. Duct
cross-sectional area shall be same as
opening free area.
iii. Horizontal ducts. Minimum free area of 1
square inch (6.5cm2) per 2,000 Btu per
hour input of all equipment in space. Duct
cross-sectional area shall be same as
opening free area.
g.Ventilation Duct Louvers and Grilles. Equip
outside openings with louvers to prevent
entrance of rain and snow, and screens to
prevent entrance of insects and rodents.
Louvers and grilles must be fixed in open
position or interlocked with equipment to
open automatically before burner operation.
Screens must not be smaller than ¼ inch
mesh.
Consider the blocking effect of louvers,
grilles and screens when calculating the
opening size to provide the required free
area. If free area of louver or grille is not
known, assume wood louvers have 20-25
percent free area and metal louvers and
grilles have 60-75 percent free area.
8. Connect gas service from Meter to gas control
assembly in accordance with Local Piping Codes and
requirements of Gas Company, see Figure 1. They may
require piping of larger size than Control Assembly
Connection, especially if run from meter is long or
includes several elbows. (See Figure 1 for size of Gas
Connection to gas control assembly).
Table 1: Maximum Capacity of Schedule 40 Pipe in CFH For Natural Gas Pressures of ½ psig or Less
Length
[Feet]
0.3 Inch w.c. Pressure Drop
½
¾
1
1¼
½
¾
1
1¼
10
132
278
520
1,050
175
360
680
1,400
20
92
190
350
730
120
250
465
950
30
73
152
285
590
97
200
375
770
40
63
130
245
500
82
170
320
660
50
56
115
215
440
73
151
285
580
60
50
105
195
400
66
138
260
530
70
46
96
180
370
61
125
240
490
80
43
90
170
350
57
118
220
460
90
40
84
160
320
53
110
205
430
100
38
79
150
305
50
103
195
400
Table 2: Equivalent Length of Fittings
Fitting
Table 3: Specific Gravity Correction Factors for
Natural Gas
Nominal Pipe Size
½
¾
1
1¼
45° Ell
0.7
1
1.2
1.6
90° Ell
1.6
2.1
2.6
3.5
Tee (As Elbow)
3.1
4.1
5.2
6.9
This piping is to be supplied by the installer and must
include a trap, a ground joint union and a manual
shutoff valve upstream of the gas control assembly
outside of the jacket when codes require, see Figure 1.
A pipe thread compound resistant to the action of
liquefied petroleum gases should be applied to all
threaded joints in the gas piping. Pressure testing of the
Gas Supply Piping Boiler and its connections is
required before placing the boiler in operation.
The boiler and shutoff valve must be disconnected from
the gas supply piping system during any pressure
testing at pressures greater than ½ psig (3.5kPa).
The boiler must be isolated from the gas supply piping
system by closing its individual manual shutoff valve
during any pressure testing of the gas supply piping
system at pressures equal to or less than ½ psig
(3.5kPa).
0.5 Inch w.c. Pressure Drop
Recommended sizing of gas supply
piping to boiler for natural gas - shall
be such as to provide the required supply of gas without
undue loss of pressure between meter and the boiler.
Gas supply piping should be sized in accordance with
the Tables 1, 2 and 3. The following shall be taken into
account:
Specific
Gravity
Correction
Factor
Specific
Gravity
Correction
Factor
0.50
1.10
1.30
1.07
0.55
1.04
1.40
1.04
0.60
1.00
1.50
1.00
0.65
0.96
1.60
0.97
0.70
0.93
1.70
0.94
0.75
0.90
---
---
0.80
0.87
---
---
A. Allowable loss of pressure to assure a burner
manifold pressure of 3½" (8.9cm) water for natural
gas.
B. Supply of gas to be provided in cubic feet.
C. Length of piping and number of fittings.
D. Specific gravity of gas.
E. Correction factor for specific gravity.
9. BOILER PIPING
CAUTION
Failure to properly pipe boiler may result in
improper operation and damage to boiler or
building.
A. Clearances - Hot water pipes do not require
clearance from combustible construction.
B. Install drain valve and safety relief valve as shown
in Figures 1 and 3. Note - Safety relief valve must
be in vertical position.
C. Pipe safety relief valve discharge to floor.
Figure 4: Recommended Piping
for Combination Heating & Cooling
(Refrigeration) Systems
Figure 3: Recommended Water Piping for
Zone Valve Zoned Heating Systems
WARNING
Safety relief valve discharge piping must be
piped near floor to eliminate potential of severe
burns. Do not pipe in any area where freezing
could occur. Do not install any shut-off valves.
D. Install circulator with flanges, gaskets and bolts
provided. Five foot long circulator harness allows
circulator to be mounted on supply or return.
Connect harness to circulator and secure any excess
conduit.
E.For heating only system piping, see Figure 3.
Consult also I=B=R Installation Guides.
F.For space heating and domestic water heating with
Alliance SL™ water heater (intermittent circulation
only); install Alliance SL™ water heater as a
separate heating zone. Refer to Alliance SL™
Installation, Operating and Service Instructions for
additional information.
G. If this boiler is used in connection with refrigeration
systems, the boiler must be installed so that the
chilled medium is piped in parallel with the heating
boiler using appropriate valves to prevent the chilled
medium from entering the boiler, see Figure 4. Also
consult I=B=R Installation and Piping Guides.
If this Boiler is connected to heating coils located in
air handling units where they may be exposed to
refrigerated air, the boiler piping must be equipped
with flow control valves to prevent gravity
circulation of boiler water during the
operation of the cooling system.
H. Use a boiler bypass if the boiler is to be
operated in a system which has a large
volume or excessive radiation where low
boiler water temperatures may be
encountered (i.e. converted gravity
circulation system, etc.).
Install a pipe tee at the boiler return along
with a second tee in the supply piping as
shown in Figure 3. The bypass should be the same
size as the supply and return lines with valves
located in the bypass and supply outlet as illustrated
in Figure 3 in order to regulate water flow to
maintain higher boiler water temperatures.
Set the boiler supply valve to fully open position,
and the boiler bypass valve to half throttle. Operate
the boiler and adjust the bypass valve to achieve
180°F to 200°F supply water temperature by closing
the bypass valve to decrease supply temperature or
opening the bypass valve to increase water
temperature. If the bypass valve is fully opened and
the boiler water temperature is still below 180°F,
slowly begin closing the boiler supply valve to
achieve 180°F to 200°F supply water temperature.
Caution: Never fully close the boiler supply valve.
I. A hot water boiler installed above radiation level
must be provided with a low water cutoff device as
part of the installation.
If a low water cut-off is required, it must be
mounted in the system piping above the boiler.
The minimum safe water level of a hot water boiler
is just above the highest water containing cavity of
the boiler; that is, a hot water boiler must be full of
water to operate safely.
Refer to Section VI for low water cut-off piping and
wiring instructions.
J. If it is required to perform a long term pressure test
of the hydronic system, the boiler should first be
isolated to avoid a pressure loss due to the escape of
air trapped in the boiler.
To perform a long term pressure test including the
boiler, ALL trapped air must first be removed from
the boiler.
A loss of pressure during such a test, with no visible
water leakage, is an indication that the boiler
contained trapped air.
K. Oxygen Corrosion:
Oxygen contamination of the boiler water will cause
corrosion of the iron and steel boiler components,
which can lead to failure. As such, any system must
be designed to prevent oxygen absorption in the first
place or prevent it from reaching the boiler.
Problems caused by oxygen contamination of boiler
water are not covered by U.S. Boiler Company's
standard warranty.
There are many possible causes of oxygen
contamination such as:
1. Addition of excessive make-up water as a result
of system leaks.
2. Absorption through open tanks and fittings.
3. Oxygen permeable materials in the distribution
system.
In order to insure long product life, oxygen
sources should be eliminated. This can be
accomplished by taking the following measures:
1. Repairing system leaks to eliminate the need for
addition of make-up water.
2. Eliminating open tanks from the system.
3. Eliminating and/or repairing fittings which allow
oxygen absorption.
4. Use of non-permeable materials in the
distribution system.
5. Isolating the boiler from the system water by
installing a heat exchanger.
10.INSTALL DRAFT HOOD without modification on
outlet of flue collector (See Figure 1). Secure with sheet
metal screws.
WARNING
Do not alter boiler draft hood or place any
obstruction or non-approved damper in the
breeching or vent system. Flue gas spillage can
occur. ETL certification will become void.
11. Install blocked vent switch
The blocked vent switch assembly shipped taped to the
top of the boiler includes a power cord and a switch
attached to a mounting bracket. The mounting bracket
has a three tooth staggered comb stamping at one end
with a #10 sheet metal screw in the center tooth.
A. Untape the blocked vent switch assembly from the
top of the boiler and uncoil the power cord.
Figure 6
B. Pinch the black strain relief bushing installed in the
jacket right side panel to dislodge it from the jacket
and pull just enough of the black power cord out so
the blocked vent switch will reach the near side of
the draft hood skirt. Do not pull out more power
cord than necessary.
C. Position the mounting bracket (with switch attached)
onto the lower edge of the draft hood skirt by
locating the center tooth (with the #10 sheet metal
screw) on the outside and the other two teeth inside
the draft hood skirt. See Figure 6.
D. Slide the mounting bracket up tight against the
lower edge of the draft hood skirt, so that the #10
sheet metal screw is above the skirt's stiffening rib.
E. Secure the bracket in this position by tightening the
#10 sheet metal screw against the outer surface of
the draft hood skirt.
F. Reinsert the excess power cord through the jacket
side panel hole to take the slack out of the power
cord running up to the blocked vent switch.
G. Reposition the strain relief bushing around the
power cord at the jacket side panel, pinch the two
halves of the bushing together, and snap it back into
the hole in the jacket side panel to secure the power
cord to the jacket.
H. Be sure the power cord, mounting bracket, and
switch are secure and located as shown in Figure 6.
Figure 7: Plug-in Damper Installation
WARNING
Failure to properly install and use this Blocked
Vent Switch may result in property damage,
personal injury or loss of life.
12.TO MEET FEDERALLY MANDATED EFFICIENCIES, THIS BOILER MUST BE EQUIPPED WITH A VENT DAMPER.
OPEN the VENT DAMPER CARTON and remove
the Installation Instructions. READ THE INSTALLATION INSTRUCTIONS THOROUGHLY before
proceeding.
The automatic gas control valve supplied on each
Series 2® boiler provides the redundancy referenced in
the vent damper Installation Instructions.
CAUTION
Do not use one vent damper to control two heating
appliances.
A. The vent damper should be the same size as the
outlet of the Draft Hood. (See Figure 1) Unpack the
damper carefully - DO NOT FORCE IT CLOSED!
Forcing the damper may damage the gear train and
void the warranty. The damper assembly includes a
prewired connection harness for use on all 24V
Standing Pilot or electronic ignition control systems.
B. Mount the vent damper assembly after the draft
hood, as close to the draft hood as practicable
without modification to the draft hood or vent
damper. (Refer to Figure 7 and to instructions
packed with the vent damper for specific
instructions). This is a must for the wiring harness to
fit and the damper position indicator to be visible to
the users.
NOTICE
Provide adequate clearance for servicing.
WARNING
Provide 6" (15.2cm) minimum clearance between
damper and combustible construction.
C. Install the 90° BX connector attached to the flexible
conduit in the 7/8" knockout on the left side of the
jacket. Plug the factory wired Vent Damper Harness
into the polarized receptacle. Install a cable clamp
around the flexible conduit and attach to the Jacket
top panel. (See Figure 7).
NOTICE
Please refer to the specifications, installation
instructions and troubleshooting guide packed
in the vent damper carton for complete detailed
installation instructions. Also refer to Figure 7 in
this manual.
D Continuous Ignition (Standing Pilot) Only. Remove
knockout from vent damper blade.
E. Size 202 Only. Install 4" x 3" reducing fitting on
vent damper outlet.
13.Install vent connector from reducing
fitting (202 Only), draft hood or damper to chimney, see
Figure 8.
boiler is served by the damper device. Installation
per paragraph 12 complies with this provision.
E. Where two or more appliances vent into a common
vent, the area of the common vent should at least
equal the area of the largest vent plus 50% of the
area in the additional vents. Do not connect the vent
of this appliance into any portion of mechanical
draft system operating under positive pressure.
F.Vent pipe should have the greatest possible initial
rise above the draft hood consistent with the head
room available and the required clearance from
adjacent combustible building structure. Vent Pipe
should be installed above the bottom of chimney to
prevent blockage.
G.Vent pipe should slope upward from draft hood to
chimney not less than one inch in four feet. Doivent
présenter des tronçons horizontaux dont la pente
montante est d’au moins ¼ po par pied (21 mm/m)
entre la chaudière et l’évent. No portion of vent
pipe should run downward or have dips or sags.
Vent pipe must be securely supported. Les sections
horizontales doivent être supportées pour prévenir le
fléchissement.
H.Vent pipe must be inserted into but not beyond
inside wall of chimney liner. Seal tight between vent
pipe and chimney.
I. Do not install non-listed (AGA, CGA, CSA, ETL or
UL) vent damper or other obstruction in vent pipe.
Figure 8: Typical Vent Installation
DANGER
Inspect existing chimney before installing boiler.
Failure to clean or replace perforated pipe or tile
lining will cause severe injury or death.
A.Vent installation shall be in accordance with local
building codes; or the local authority having
jurisdiction; or the National Fuel Gas Code, ANSI
Z223.1/NFPA 54; or the Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning
Appliances, ANSI/NFPA 211. Both of the
aforementioned standards, ANSI Z223.1 and ANSI/
NFPA 211, specify Type B and Type L double wall
metal vents and fire clay tile lined masonry
chimneys as suitable chimney constructions for
Category I, draft hood equipped appliances, such as
this Series 2® boiler. Both standards prohibit the use
of unlined masonry construction as a chimney, with
the exception in ANSI Z223.1/NFPA 54 that "Where
permitted by the authority having jurisdiction,
existing chimneys shall be permitted to have their
use continued when an appliance is replaced by an
appliance of similar type, input rating, and
efficiency." ANSI/NFPA 211 prohibits the use of
single wall metal vent as a chimney, while ANSI
Z223.1 allows it under very restrictive conditions.
In Canada refer to the Natural Gas and LP
Installation Code, CAN/CSA-B149.1.
B. Do not connect into same leg of chimney serving an
open fireplace.
C. Inspect chimney for obstructions or restrictions and
remove. Clean chimney if necessary.
D.Vent pipe to chimney must not be smaller than outlet
on draft hood or damper. Although single wall vent
pipe may be used, Type B is recommended. The
venting system must be arranged so that only the
10
WARNING
14.If an existing boiler is removed When an existing boiler is removed from a common
venting system, the common venting system is likely to
be too large for proper venting of the appliances
remaining to it.
At the time of removal of an existing boiler, the
following steps shall be followed with each
appliance remaining connected to the common
venting system placed in operation, while the other
appliances remaining connected to the common
venting system are not in operation:
A. Seal any unused openings in the common venting
system.
B. Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and other
deficiencies which could cause an unsafe condition.
C. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn
on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maxi­mum
speed. Do not operate a summer exhaust fan. Close
fireplace dampers.
D. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermo­stat so appliance will operate
continuously.
E. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
F. After it has been determined that each appliance
remain­ing connected to the common venting system
properly vents when tested as outlined above, return
doors, win­dows, exhaust fans, fireplace dampers and
any other gas burning appliance to their previous
conditions of use.
G. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1 and/or CAN/CSA B149.1, Installation
Codes. When resizing any portion of the common
venting system, the common venting system should
be resized to approach the minimum size as
determined using the National Fuel Gas Code,
ANSI Z223.1 and/or CAN/CSA B149.1, Installation
Codes.
Au moment du retrait d’une chaudière existante, les
mesures suivantes doivent être prises pour chaque
appareil toujours raccordé au système d’evacuation
commun et qui fonctionne alors que d’autres
appareils toujours raccordés au système
d’évacuation ne fonctionnent pas:
A. Sceller toutes les ouvertures non utilisées du
système d’évacuation.
B. Inspecter de facon visuelle le système d’évcuation
pour déterminer la grosseur et l’inclinaison
horizontale qui conviennent et s’assurer que le
système est exempt d’obstruction, d’étranglement,
de fuite, de corrosion et autres défaillances qui
pourraient présenter des risques.
C. Dans la mesure du possible, fermer toutes les portes
et les fenêtres du bâtiment et toutes les portes entre
l’espace où les appareils toujours raccordés au
système d’évacuation sont installés et les autres
espaces du bâtiment. Mettre en marche les
sécheuses, tous les appareils non raccordés au
système d’évacuation commun et tous les
ventilateurs d’extraction comme les hottes de
cuisinière et les ventilateurs des salles de bain.
S’assurer que ces ventilateurs fonctionnent à la
vitesse maximale. Ne pas faire fonctionner les
ventilateurs d’été. Fermer les registres des
cheminées.
D. Mettre l’appareil inspecté en marche. Suivre les
instructions d’allumage. Régler le thermostat de
facon que l’appareil fonctionne de facon continue.
E. Faire fonctionner le brùleur principal pendant 5 min
ensuite, déterminer si le coupe-tirage déborde à
l’ouverture de décharge. Utiliser la flamme d’une
allumette ou d’une chandelle ou la fumée d’une
cigarette, d’un cigare ou d’une pipe.
F. Une fois qu’il a été déterminé, selon la méthode
indiquée ci-dessus, que chaque appareil raccordé au
système d’évacuation est mis à l’air libre de facon
adéquate. Remettre les portes et les fenêtres, les
ventilateurs, les registres de cheminées et les
appareils au gaz à leur position originale.
G. Tout mauvais fonctionnement du système
d’évacuation commun devrat être corrigé de facon
que l’installation soit conforme au National Fuel
Gas Code, ANSI Z223.1 et (ou) aux codes
d’installation CAN/CSA-B149.1. Si la grosseur
d’une section du système d’évacuation doit être
modifiée, le système devrait être modifié pour
respecter les valeurs minimales des tableaux
pertinents de l’appendice F du National Fuel Gas
Code, ANSI Z223.1 et (ou) des codes d’installation
CAN/CSA-B149.1.
15.Install a room thermostat on an inside
wall about four feet above floor. Never install
thermostat on an outside wall or where it will be
influenced by drafts, hot or cold water pipes, lighting
fixtures, television, rays of the sun or near a fireplace.
Keep large furniture away from thermostat so there will
be free movement of room air around this control.
Table 4: Wiring Diagrams and Heat Anticipator Settings
Ignition Type
Circulation Method
Thermostat Heat Anticipator
Setting [Amps]
Wiring
Diagram Figure
Continuous
(Standing Pilot)
Intermittent
0.6
11
Constant/Gravity
1.0
14
Intermittent
0.6
12
Constant/Gravity
1.0
15
Electronic
If system tends to overheat above thermostat's temperature setting, reduce heat anticipator setting by
0.1 or 0.2 amps. If system tends to shortcycle without reaching desired room temperature, increase heat
anticipator setting by 0.1 or 0.2 amps.
11
Heat Anticipator in Thermostat should be set to match
the requirements of the control to which it is connected.
See Table 4. If system tends to overheat above the
thermostat's temperature setting, reduce heat anticipator
setting by .1 or .2 amps. If system tends to short cycle
without reaching desired room temperature, increase
heat anticipator setting by .1 or .2 amps.
17.Vent Damper Sequence of Operation.
16.Install electric wiring in accordance with
National Electric Code or the Canadian Electrical Code
and local regulations. See Figures 11 through 16 for
applicable wiring diagram. A separate electrical circuit
must be run from the main electrical service with an
over-current device/disconnect in the circuit. A service
switch is recommended and may be required by some
local jurisdictions. When installed, the boiler must be
electrically grounded in accordance with local codes or,
in the absence of local codes, with the National
Electrical Code, ANSI/NFPA 70, and/or the CSA C22.1
Electrical Code, if an external electrical source is
utilized.
For zone valve wiring, a separate 24V transformer is
required rather than attempting to use the boiler
mounted control. Consult zone valve manufacturer for
assistance.
See Figure 9.
A. The Vent Damper is continuously powered at
Terminal 1.
B. When there is a call for heat, the damper relay coil is
energized through Terminal 5 if all limits ahead of
the damper are satisfied.
C. The relay coil closes contacts which energize the
damper motor, causing the damper to open.
D. When the damper blade reaches the fully open
position, power is sent back to the ignition circuit
through Terminal 2 and the damper motor is deenergized.
E. When the call for heat is satisfied, the damper relay
coil is de-energized - closing contacts which
energize the damper motor. This causes the damper
to close. When the damper blade reaches the fully
closed position, the damper motor is de-energized.
Power Failure - The damper blade will stop in
the position it was in when power failed.
(Combustion can never take place unless the damper
blade is in the fully open position.)
Figure 9: Vent Damper Schematic Wiring Diagram
CAUTION
This boiler contains controls which may cause the boiler to shut down and not restart without service. If
damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if
the boiler is inoperative.
CAUTION
Avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc.
are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and
inspected daily to insure proper operation.
12
Figure 11: Wiring Diagram, 24 Volt Standing Pilot and Intermittent Circulation
Sequence of Operation
Normal Operation
1. When the thermostat call for heat, the vent damper
will open (see paragraphs 17A through 17D). The
circulator is started through a relay and at the same
time the gas valve is energized allowing main gas
flow and ignition of main burners.
2. Where condensation of flue gas is encountered in
boiler flues a reverse acting circulator control should
be installed to stop the circulator before the boiler
water temperature drops to that which flue gas
condensation may occur.
3. After the thermostat is satisfied the main valve will
close and main burner flames will be extinguished.
The vent damper will close (see paragraph 17E).
SAFETY SHUTDOWN
1.High Limit Switch
In the event excessive boiler water temperature is
developed the high limit switch will open
interrupting power to the gas valve. The main
burners will be extinguished immediately, and the
vent damper will close at the same time, but the
circulator will continue to operated. Normal
operation will be resumed when the boiler water
temperature drops to a point where the high limit
switch closes.
2. Blocked Vent Switch
In the event excessive blockage in the vent system is
developed the blocked vent switch will open
interrupting power to the gas valve. The main
burners will be extinguished immediately, the
circulator will continue to operate, and the vent
damper will remain open until the thermostat is
turned off. The source of blockage must be
corrected by trained and skilled personnel from a
qualified service agency before resetting switch.
3. Flame Rollout Switch
In the event excessive blockage in the boiler section
flue passageways is developed the flame rollout
switch will open interrupting power to the gas valve.
The main burners will be extinguished immediately,
the circulator will continue to operate and the vent
damper will remain open until the thermostat is
turned off. If the flame rollout switch is activated do
not attempt to place the boiler in operation. The
source of blockage must be corrected and the flame
rollout switch replaced by trained and skilled
personnel from a qualified service agency.
4. Pilot
The thermocouple proves pilot flame and in the
absence of such within 45-90 seconds causes the
combination gas valve, which is equipped with a
100% shut-off provision, to be de-energized, thus,
preventing main gas or pilot gas flow.
13
Figure 12: Wiring Diagram, Electronic Ignition (EI), Intermittent Circulation
SEQUENCE OF OPERATION
Normal Operation
1. When the thermostat calls for heat, the relay is
energized. The circulator starts and the vent damper
opens (see Paragraphs 17A through 17D). When the
damper blade reaches the fully open position, the
ignition module is energized opening the pilot valve
and energizing the igniter to ignite the pilot burner.
2. Sensor proves presence of pilot flame. Main valve
opens to ignite main burners.
3. The burners and circulator will operate
simultaneously until the thermostat is satisfied.
4. After thermostat is satisfied, ignition module is deenergized, extinguishing pilot and main flame. Vent
damper closes (see paragraph 17E).
Safety Shutdown
1. Limit: Automatically interrupts main burner
operation when water temperature exceeds set point.
Maximum allowable temperature is 250°F. Normal
operation resumes when water temperature falls
below set point.
14
2. Blocked Vent Switch: Automatically interrupts
main burner operation when excessive vent system
blockage occurs. Control is a multiple use device. If
blocked vent switch is activated do not attempt to
place boiler in operation. Correct source of blockage
and reset blocked vent switch.
3. Flame Roll-out Switch: Automatically interrupts
boiler operation when flames or excessive heat are
present in vestibule. Control is single use device. If
flame roll-out switch is activated do not attempt to
place boiler in operation. Correct source of blockage
and replace flame roll-out switch.
4. Igniter/Sensor: senses pilot flame and causes
ignition module to turn off main burner and pilot
burner gas flow should pilot burner flame
extinguish. Five to six minutes after shutdown,
ignition module restarts ignition sequence.
5. For Electronic Ignition Trouble Shooting Guide, see
Page 25 of this manual.
Figure 13: Wiring Diagram, 24 Volt Standing Pilot with Continuous or Gravity Circulation
Sequence of Operation
Normal Operation
1. When the thermostat call for heat, the vent damper
will open (see paragraphs 17A through 17D). The
gas valve is energized allowing main gas to flow and
operation of the main burners.
2. Where condensation of flue gas is encountered in
boiler flues a reverse acting circulator control should
be installed to stop the circulator before the boiler
water temperature drops to that which flue gas
condensation may occur.
3. After the thermostat is satisfied the main valve will
close and main burner flames will be extinguished.
The vent damper will close (see paragraph 17E). If
the boiler is so equipped, circulator will continue to
run.
Safety Shutdown
1.High Limit Switch: In the event excessive boiler
water temperature is developed the high limit switch
will open interrupting power to the gas valve. The
main burners will be extinguished immediately.
Normal operation will be resumed when the boiler
water temperature drops to a point where the high
limit switch closes.
2. Blocked Vent Switch: In the event excessive
blockage in the vent system is developed the
blocked vent switch will open interrupting power to
the gas valve. The main burners will be extinguished
immediately and the vent damper will remain open
until the thermostat is turned off. The source of
blockage must be corrected by trained and skilled
personnel from a qualified service agency before
resetting switch.
3. Flame Rollout Switch: In the event excessive
blockage in the boiler section flue passageways is
developed the flame rollout switch will open
interrupting power to the gas valve. The main
burners will be extinguished immediately and the
vent damper will remain open until the thermostat is
turned off. If the flame rollout switch is activated do
not attempt to place the boiler in operation. The
source of the blockage must be corrected and the
flame rollout switch replaced by trained and skilled
personnel from a qualified service agency.
4. Pilot: The thermocouple proves pilot flame and in
the absence of such within 45-90 seconds causes the
combination gas valve, which is equipped with a
100% shut-off provision, to be de-energized, thus,
preventing main gas or pilot gas flow.
15
Figure 14: Wiring Diagram, Electronic Ignition (EI), Continuous or Gravity Circulation
SEQUENCE OF OPERATION
NORMAL OPERATION
1. When the thermostat calls for heat the vent damper
opens (see Paragraphs 17A through 17D). When the
damper blade reaches the fully open position, the
ignition module is energized opening the pilot valve
and energizing the igniter to ignite the pilot burner.
2. Sensor proves presence of pilot flame. Main valve
opens to ignite main burners.
3. The burners will operate until the thermostat is
satisfied.
4. When thermostat is satisfied, ignition module is deenergized, extinguishing pilot and main flame. If
boiler is equipped with circulator, circulator will
continue to run. Vent damper closes (see Para-graph
17E).
SAFETY SHUTDOWN
1. Limit: Automatically interrupts main burner
operation when water temperature exceeds set point.
Maximum allowable temperature is 250°F. Normal
operation resumes when water temperature falls
below set point.
16
2. Blocked Vent Switch: Automatically interrupts
main burner operation when excessive vent system
blockage occurs. Control is a multiple use device. If
blocked vent switch is activated do not attempt to
place boiler in operation. Correct source of blockage
and reset blocked vent switch.
3. Flame Roll-out Switch: Automatically interrupts
boiler operation when flames or excessive heat are
present in vestibule. Control is single use device. If
flame roll-out switch is activated do not attempt to
place boiler in operation. Correct source of blockage
and replace flame roll-out switch.
4. Igniter/Sensor: senses pilot flame and causes
ignition module to turn off main burner and pilot
burner gas flow should pilot burner flame
extinguish. Five to six minutes after shutdown,
ignition module restarts ignition sequence.
5. For Electronic Ignition Trouble Shooting Guide, see
Page 25 of this manual.
Figure 15: Wiring Schematic, Zone Valves
Figure 16: Wiring Schematic, Zone Circulators
17
II. Operating Instructions
Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the
boiler underwent tests specified in American National Standard for Gas-Fired Low-Pressure Steam and Hot Water Boilers, ANSI
Z21.13b-1994.
1. Main burner check - Check main burners to
see that they were not dislodged during shipment. Rear
of burners should be in the slots in the rear of burner
tray and the front of the burners should be seated
completely on the orifices.
2. Initial start A. Fill entire heating system with
water and vent air from system. Use the
following procedure on a Series Loop System
equipped with zone valves. (See Figure 3).
1. Close isolation valve in boiler supply piping.
2. Isolate all circuits by closing zone valves or
balancing valves.
3. Attach a hose to hose bib located just below
isolation valve in boiler supply piping. (Note Terminate hose in five gallon bucket at a suitable
floor drain or outdoor area).
4. Starting with one circuit, open zone valve.
5. Open hose bib.
6. Open fill valve (Make-up water line should be
located directly above isolation valve in boiler
supply piping).
7. Allow water to overflow from bucket until
discharge from hose is bubble free for 30
seconds.
8. Open zone valve to the second zone to be
purged, then close the first. Repeat this step until
all zones have been purged, but always have one
zone open. At completion, open all zone valves.
9. Close hose bib, continue filling the system until
the pressure gauge reads 12 psi. Close fill valve.
(Note - If make-up water line is equipped with
pressure reducing valve, system will
automatically fill to 12 psi. Leave globe valve
open).
10. Open isolation valve in boiler supply piping.
11. Remove hose from hose bib.
B. Turn room thermostat to lowest setting.
C. Be sure that gas to pilot and main burners has been
off for at least five minutes and vent damper (if
used) has been in the open position.
D. Turn "OFF" the electric switch serving boiler.
E. Open valve on main gas line at meter.
F. Purge air from gas piping. This
procedure will vary with equipment furnished but in
all cases adequate ventilation must be provided
and no smoking or open flame permitted. To
determine which of the procedures outlined in
succeeding paragraphs is applicable, match suffix of
18
Figure 17: Schematic Pilot and Gas Piping
Continuous Ignition (Standing Pilot)
Figure 18: Schematic Pilot and Gas Piping
Electronic Ignition (EI)
boiler model found on Rating Label with paragraph
heading:
1. Standing Pilot Models (Suffix C):
a. Keep electric switch "OFF".
b. Open Manual Shut-off Valve upstream of
Combination Gas Valve.
c. Disconnect Pilot Tubing at gas valve (Purge
must not be into combustion chamber).
d. Turn Main Gas Knob on Combination Gas
Valve to "Pilot" Position. Depress and hold
in this position until purging is complete.
Turn Main Gas Knob to "off" position.
Figure 19: Top View of VR Gas Valves
Figure 20: Operating Instructions, VR8204 and VR8304 Gas Valves
19
e. Reconnect pilot tubing and check pipe
and fittings from meter to combination
Gas Valve for leaks using soap
solution or other approved method.
2. Electronic Ignition Models (Suffix I):
a. Turn "ON" electric switch serving
boiler.
b. Open Manual Shut-off Valve upstream
of Combination Gas Valve.
c. Loosen or remove Inlet Pressure Tap
Plug in Combination Gas Valve and
when purging is complete, tighten or
replace plug. See Figure 19.
d. Check pipe and fittings from meter to
Combination Gas Valve using soap
solution or other approved methods.
CAUTION
e. Test gas piping and connections
between Combination Gas Valve and
manifold, orifices, and pilot piping for
leaks after boiler is operating. Use
soap solution or other approved
method.
3. INSTRUCTIONS TO PUT THE BOILER IN
OPERATION.
A. See Figure 20 for electronic ignition (EI).
Electronic Ignition Modules with LED
indicators. Table 5 cross-references the
ignition module terminal designations to the
ignition terminal numbers in the wiring ladder
diagrams. Table 6 provides green LED status
codes and recommended service action where
applicable.. See Figure 21A for Location of
LED. See Figure 28 for Troubleshooting
Guide.
1. Flame Current Measurement Procedure.
See Figure 21B “Measuring pilot flame
current with micro-ammeter”
a. Pilot flame current in micro amps can
be measured using any standard
micro-ammeter by inserting the meter
probes into the module holes labeled
FLAME CURRENT as shown in
Figure 21B.
b. Flame current must be measured
with pilot valve open/pilot lit but the
main valve closed.
c. Disconnect MV lead wire from the
module before measuring flame
current. Trying to measure the pilot
flame current in series with the wiring
will not yield the accurate reading.
20
Figure 21A: Location of LED
Table 5: Ignition Module Terminal Cross-Reference
Ignition Module
Terminal Designation
Wiring Ladder Diagram
Terminal Number
MV
1
MV/PV
2
PV
3
GND
4
24V (GND)
5
24V
6
SPARK
9
Figure 21B: Measuring Pilot Flame Current
with Micro-ammeter
d. The minimum steady pilot flame signal
must be 1 μAmp (microampere) DC (direct
current).
e. For reliable operation the flame current
should be 2 μAmp or greater.
f. To ensure adequate flame current:
i. Turn off boiler power at circuit breaker
or fuse box
ii. Clean the flame rod with emery cloth if
required
iii. Make sure electrical connections are
clean and tight, and wiring not damaged,
repair/replace as needed
iv. Check for igniter/sensor cracked ceramic
insulator, replace if needed
v. Check the pilot flame. It must be blue,
steady and envelop the flame sensing rod
3/8” to ½”.
vi. If needed, adjust pilot flame by turning
the gas valve pilot adjustment screw
clockwise to decrease or
counterclockwise to increase pilot flame.
Always reinstall pilot adjustment screw
cover and tighten securely upon
completion to assure proper gas valve
operation.
g. Reconnect MV lead wire to the module upon
satisfactory completion of pilot flame
current measurement.
h. Check the pilot burner operation/ignition
sequence during ignition cycle:
i. Restore boiler power at circuit breaker or
fuse box.
ii. Set thermostat to call for heat.
iii.Watch ignition sequence at burner.
iv. If spark does not stop after pilot lights,
replace ignition module.
v. If main burners do not light or if main
burners light but system locks out, check
the module ground wire and gas control
as described in Figure 28 “ Honeywell
Electronic Ignition Troubleshooting
Guide”.
Table 6: Green LED Flame Codes
Green LED
Flash
Codea
OFF
Next System Action
Recommended Service Action
No “Call for Heat”
N/A
None
Flash Fast
Power up - internal check
N/A
None
Heartbeat
Normal startup - ignition sequence
started (including prepurge)
N/A
None
Device in run mode.
“x” = flame current to the nearest µA.
N/A
None
4 Seconds ON
then “x” flashes
a
Indicates
2
5 minute Retry Delay
- Pilot flame not detected during trial for
ignition
Initiate new trial for ignition after retry
delay completed.
If system fails to light on next trial for ignition
check gas supply, pilot burner, spark and
flame sense wiring, flame rod contamination or
out of position, burner ground connection.
3
Recycle
- Flame failed during run
Initiate new trial for ignition. Flash code
will remain through the ignition trial until
flame is proved.
If system fails to light on next trial for ignition,
check gas supply, pilot burner, flame sense
wiring, contamination of flame rod, burner
ground connection.
4
Flame sensed out of sequence
If situation self corrects within 10
seconds, control returns to normal
sequence. If flame out of sequence
remains longer than 10 seconds, control
will resume normal operation 1 hour
after error is corrected.
Check for pilot flame. Replace gas valve if pilot flame present. If no pilot flame, cycle “Call
for Heat.” If error repeats, replace control.
6
Control Internal Error
Control remains in wait mode. When
the fault corrects, control resumes
normal operation.
Cycle “Call for Heat”. If error repeats, replace
control.
7
Flame rod shorted to ground
Control remains in wait mode. When
the fault corrects, control resumes
normal operation.
Check flame sense lead wire for damage or
shorting. Check that flame rod is in proper
position. Check flame rod ceramic for cracks,
damage or tracking.
8
Low secondary voltage supply- (below
15.5 Vac)
Control remains in wait mode. When
the fault corrects, control resumes
normal operation.
Check transformer and AC line for proper input
voltage to the control. Check with full system
load on the transformer.
Flash Code Descriptions:
-
Flash Fast: rapid blinking
-
Heartbeat: Constant ½ second bright, ½ second dim cycles.
-
4 second solid on pulse followed by “x” 1 second flashes indicates flame current to the nearest µA. This is only available in run mode.
-
A single flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then repeats the sequence.
21
22
Figure 22: Lighting Instructions
B. See Figure 22 for continuous ignition system
(standing pilot).
first two items in order to utilize the formula
below. The gas meter should then be clocked for
three (3) minutes with stop watch and
substituting the appropriate values in the formula
below, determine what the gas flow should be in
this 3 minute period to give the input shown on
the Rating Label:
4. CHECK GAS INPUT RATE TO BOILER
NOTICE
USA boilers built for installation at altitudes greater
than 2,000 feet above sea level have been specially
orificed to reduce gas input rate 4 percent per 1,000 feet
above sea level per the National Fuel Gas Code, NFPA
54/ANSI Z223.1, Section 8.1.2 and Appendix F.
Canadian boilers' orifice sizing is indicated on the rating
label. High altitude boiler models are identifiable by
the fourth digit after the dash in the model number. 2:
0-2000', 4 or 5: above 2000'.
A. Input Rate and Maximum Inlet Pressure shown on
Rating Label must not be exceeded. Inlet pressure
must not be lower than minimum inlet pressure
shown on Rating Label.
B. All Rate checks and all adjustments are to be made
while boiler is firing - all other appliances connected
to the same meter as the boiler must be off.
C. With boiler off, water Manometer or water column
gauge should be connected to a shut-off valve
installed in the 1/8" outlet pressure tap in the gas
valve (see Figure 19). By installing gas valve
upstream of manometer, gas pressure can be
introduced gradually - without shut-off valve, surge
of pressure when boiler is turned on, could blow
liquid out of manometer. Replace plug in gas valve
when rate check is finished.
D. LP Gas Input:
Adjust Regulator on Gas Valve so that manifold
pressure is 10 inches water column. Turning
Regulator Adjusting Screw Clockwise increases
pressure. Counterclockwise rotation decreases
pressure.
E. Natural Gas Input
1. Appx. Input - Adjust regulator on Gas Valve so
that manifold pressure is three and a half (3½)
inches water column. Turning Regulator
Adjusting Screw Clockwise increases pressure,
Counterclockwise rotation decreases pressure. If
more accurate check on input is necessary see
(2) below.
For minor input changes readjust Regulator Gas
Valve to increase or decrease manifold pressure
to obtain corresponding increase or decrease in
gas input. If it is necessary to increase manifold
pressure more than 0.3" of water to obtain rated
input, remove orifices and drill one size larger.
Reinstall and recheck input rate.
2. Additional Check on Input - Since input is a
function of heating value, specific gravity, and
volume of gas flow contact your utility for the
Gas Input
(cu. ft.)
per 3 min.
=
Btuh Input
Heating
Value
of Gas
Multiplier
X
from
Table 3
(Btu / cu. ft.
5. MAIN BURNER FLAMES should have a clearly
defined inner cone (see Figure 23 or 24) with no yellow
tipping. Orange-yellow streaks caused by dust should
not be confused with true yellow tipping.
The main burners in this boiler will not operate cleanly
or efficiently if they are contaminated with dirt and/or
construction dust. Burners should be cleaned and the
combustion chamber vacuumed following instructions
in Section IV. Service.
Figure 23: 40mm Main Burner Flame
Figure 24: 1 Inch Main Burner Flame
23
Figure 25: Typical Pilot Flame, Honeywell Q350
6. CHECK PILOT BURNER FLAME.
A. Continuous Ignition (Standing Pilot)
LP gas Models 202 and 202X. See Figure 25.
Natural gas Models 202 through 206 and 207 with
1" diameter burners. See Figure 25.
The pilot produces a single flame. The flame should
be steady, medium hard blue enveloping 3/8 to a 1/2
inch of thermocouple.
B. Continuous Ignition (Standing Pilot)
Natural gas Models 207 with 40mm (1-9/16")
diameter burners and 208 through 210.
See Figure 26.
LP gas Models 203 through 210. See Figure 26.
The pilot produces three (3) flames. The center
flame should be steady, medium hard blue
enveloping 3/8 to a 1/2 inch of thermocouple.
C. Electronic Ignition (EI), see Figure 27.
The pilot produces three (3) flames. The center
flame should be steady, medium hard blue
enveloping 3/8 to a ½ inch of sensing probe.
Figure 27: Typical Pilot Flame, Honeywell Q348A
7. Check thermostat operation. Raise and
lower temperature setting as required to start and stop
burners.
8. Check high limit control. Jumper
Thermostat Terminals or Thermostat connections in
Limit Control. Allow burners to operate until shutdown
by limit. Remove jumper.
9. CHECK DAMPER OPERATION. Vent Damper must
be open when boiler is running. Le registre doit être
ouvert lorsque le brûleur principal de l’appareil
fonctionne. Start boiler, refer to instructions on damper
to determine if damper is in the full open position.
10.CHECK IGNITION SYSTEM SAFETY SHUT-OFF
DEVICE.
A. 24 volt-loosen thermocouple at gas valve.
B. Electronic Ignition - Remove pilot lead wires from
gas valve.
If burners do not shut down determine cause of
malfunction. Replace necessary items and check
operation.
11. COMBUSTION CHAMBER BURN-OFF
Figure 26: Typical Pilot Flame, Honeywell Q327
24
A. The mineral wool combustion chamber panels may
contain a cornstarch based binder that must be
burned out at installation to prevent odors during
subsequent boiler operation.
B.Ventilate the boiler room, set the high limit to its
maximum setting, set the thermostat to call for heat.
Allow the boiler to fire for at least an hour or until
the odor from the cornstarch has dissipated.
C. Return the high limit and thermostat to their desired
settings.
III. Trouble Shooting
Honeywell Electronic Ignition Troubleshooting Guide
"CALL FOR HEAT."
POWER TO
MODULE? (24 V
NOMINAL)
NO
CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO,
CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED)
IS MADE.
YES
30 SECOND
PREPURGE
DELAY?(S8670
ONLY)
NO
REPLACE S8670
YES
PULL IGNITION LEAD AND
CHECK SPARK AT MODULE.
SPARK
ACROSS IGNITOR/
SENSOR
GAP?
SPARK OK?
NO
REPLACE MODULE
NO
YES
CHECK IGNITION CABLE, GROUND WIRING, CERAMIC INSULATOR, AND SPARK GAP AND CORRECT.
CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING. TAKE PROTECTIVE ACTION TO SHIELD CABLE
AND BOOT FROM EXCESSIVE TEMPERATURES.
YES
TURN GAS SUPPLY ON AND
RECYCLE "CALL FOR HEAT."
CHECK THAT ALL MANUAL GAS VALVES ARE OPEN, SUPPLY TUBING AND PRESSURES ARE GOOD, AND PILOT BURNER
ORIFICE IS NOT BLOCKED (PILOT GAS FLOWING).
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL.
CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE, IF VOLTAGE IS OK, REPLACE GAS CONTROL. IF NOT,
REPLACE MODULE.
NOTE: IT MAY BE NECESSARY TO RECYCLE THE "CALL FOR HEAT" MORE THAN ONCE TO CLEAR THE PILOT SUPPLY TUBES OF AIR.
NO
PILOT BURNER
LIGHTS?
YES
SPARK
STOPS WHEN
PILOT IS
LIT?
NO
NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE "CALL FOR HEAT."
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
CLEAN FLAME ROD.
CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE.
CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE.
ADJUST PILOT FLAME.
IF PROBLEM PERSISTS, REPLACE MODULE.
NO
CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF NO VOLTAGE, REPLACE MODULE.
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL INCLUDING SAFETY CONTROLS WIRED IN THE CIRCUIT. IF
OKAY, REPLACE GAS CONTROL.
NO
NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE "CALL FOR HEAT."
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
NOTE: IF GROUND IS POOR OR ERRATIC, SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL
AT THE TIME OF CHECKOUT.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE. PILOT FLAME MUST NOT BE MOVING AROUND DUE TO
OUTSIDE AIR FLOWS, ETC.
ADJUST PILOT FLAME. CHECK GAS PRESSURE MEETS APPLIANCE SPECIFICATIONS WHILE APPLIANCE MAIN BURNER IS ON AND ALL
OTHER GAS APPLIANCES ON THE SUPPLY ARE OPERATING AT FULL RATE.
IF CHECKS ARE OKAY, REPLACE MODULE.
NO
CHECK FOR PROPER THERMOSTAT (CONTROLLER) OPERATION.
REMOVE MV LEAD AT MODULE. IF VALVE CLOSES, RECHECK TEMPERATURE CONTROLLER AND WIRING. IF NOT, REPLACE
GAS CONTROL.
YES
MAIN BURNER
LIGHTS?
YES
SYSTEM
RUNS UNTIL "CALL
FOR HEAT"
ENDS?
YES
"CALL FOR HEAT" ENDS
SYSTEM
SHUTS OFF?
Figure 28: Troubleshooting Guide, Honeywell Electronic Ignition (EI)
25
IV. Service
1. Inspection should be conducted annually. Service as
frequently as specified in paragraphs below. While
service or maintenance is being done, Electrical Power
and all Gas Supply to the Boiler must be "off".
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.
ATTENTION. Au moment de l’entretien des
commandes, étiquetez tous les fils avant
de les débrancher. Les erreurs de câblage
peuvent nuire au bon fonctionnement et être
dangereuses.
S’assurer que l’appareil fonctionne
adéquatement une fois l’entretien terminé.
2. Vent System. Vent system (see Figure 8 for typical
installation) should be checked annually for:
A. Obstructions.
B. Accumulations of soot.
C. Deterioration of vent pipe or vent accessories due to
condensation or other reasons.
D. Proper support - no sags, particularly in horizontal
runs.
E. Tightness of joints.
F. Proper vent damper operation - see Section II
Operating Instructions, paragraph 9.
G. Remove all accumulations of soot with wire brush
and vacuum, see Figure 29. Remove all
obstructions. Replace all deteriorated parts and
support properly. Seal all joints.
Reinstall Jacket Top Panel, draft hood, blocked vent
switch, damper (if boiler is so equipped), and vent
pipe.
If the flue passageways need cleaning, remove
burners as described in paragraph 4 below. Using
long handle wire or bristle flue brush and vacuum,
brush flueways thoroughly from top of boiler as
illustrated in Figure 29. Replace canopy and seal
with boiler putty. Reinstall Jacket Top Panel, draft
hood, blocked vent switch, damper (if boiler is so
equipped), and vent pipe.
NOTICE
4. Burners and firebox should be cleaned
annually, and if necessary adjusted
once a year BY a qualified service
agency.
A. To remove burners for cleaning,
changing orifice plugs, or repairs.
1. Remove the jacket front panel.
2. Disconnect pilot tubing at the gas valve. See
Figure 17.
3. Disconnect thermocouple (standing pilot) or pilot
lead wires (electronic ignition) at the gas valve.
4. 40mm burners only. Remove injection shield
assembly, where used. See Figure 30.
5. Remove wires to flame roll-out switch.
6. Remove the burner access panel.
7. Mark the location of the pilot main burner on the
manifold if the marking on manifold is missing
or obliterated.
3. Cleaning Boiler Flues, see Figure 29.
26
Flue passageways in the boiler sections should be
checked annually for any blockage or accumulation of
soot. To obtain access to flueways:
A. Remove vent pipe, damper (if boiler is so equipped),
blocked vent switch, and draft hood.
B. Remove sheet metal screws securing Jacket Top
Panel, lift panel and rotate about relief valve piping
until top of boiler is exposed.
C. Remove bolts securing Canopy to Boiler Sections.
Remove Canopy - flueways are now exposed.
D. Models with flue gas baffles only: Remove baffles
by lifting out of flueways.
Using flashlight, examine all flue passageways. If
passageways are free of soot and obstruction,
replace canopy (and flue gas baffles, if applicable),
and seal.
Figure 29: Cleaning of Vent System
and Boiler Flues
1" Burner
A. To replace orifice:
1. Disconnect pilot tubing. The Honeywell Q350
pilot orifices are insert type retained by the
compression fitting. The Honeywell Q327 and
Q348A pilot orifices are spud type screwed into
pilot burner. Replace with desired orifice. See
Key No. 5B.
2. Reconnect pilot tubing and check for leaks.
B. To replace Honeywell Q309A thermocouple in
Q327 or Q350 pilot:
1. Loosen attachment nut securing thermocouple to
barrel of pilot burner. Disconnect other end at
combination gas valve.
2. Remove thermocouple and replace with equal.
40mm Burner
C. To replace complete pilot assembly.
1. Remove machine screws holding pilot burner to
pilot bracket.
2. Disconnect pilot piping.
3. Disconnect all other leads to pilot.
4. Select pilot assembly with identical model
number, reconnect leads and pilot tubing resecure to pilot bracket.
Figure 30: Burner Cleaning and Installation
8.Hold burner at throat. Lift front of burner to
clear orifice. Burner which holds pilot can only
be removed by lifting the burner adjacent to its
right first.
9. Brush top of burners with a soft bristle brush, see
Figure 30. Vacuum burners. Check orifices to see that drilled passageways are free of lint or dirt.
10.Vacuum tip of Pilot Burner.
B. Clean Firebox by vacuuming. Exercise care
not to disturb insulation inside the base.
C. Install burners by reversing procedure used
to remove burners. Make sure burner with pilot
assembly is in same location as original installation
- see Table 8.
Check burners to see that they are located properly
in slot at rear of burner tray, see Figure 30.
Reinstall injection shield assembly (40mm burners
only, where used) and burner access panel.
Reconnect flame roll-out switch wires, pilot gas
supply, thermocouple lead or pilot lead.
D. Check main burner and Pilot flames,
see procedure Section II Operating Instructions,
paragraphs 5 and 6.
5. Check all control and damper
operation annually see procedure in Section II
Operating Instructions, paragraphs 7 through 10.
6. Removal or replacement of pilot
assembly or pilot assembly parts
If pilot assembly, thermocouple or pilot orifice need
replacing, remove main burner with pilot using
procedure described in paragraph 4.
D. To adjust or check spark gap between electrode and
hood on Honeywell Q348A pilot.
1. Use round wire gauge to check spark gap.
2. Spark gap should be 1/8 inch for optimum
performance.
E. Reinstall main burner following procedure described
in paragraph 4.
7. Lubrication
There are no parts requiring lubrication on the part of
the service technician or the User. Circulator bearings
are water lubricated.
Table 8: Pilot Burner Location
Boiler
Model
Main Burner with
Pilot Bracket *
Pilot Burner Located
Between Main
Burners *
1 Inch
40mm
1 Inch
40mm
202
1
1
1&2
---
202X
1
1
1&2
1&2
203
1
1
1&2
1&2
204
2
2
2&3
2&3
205
3
2
3&4
2&3
206
4
3
4&5
3&4
207
6
3
6&7
3&4
208
7
4
7&8
4&5
209
8
4
8&9
4&5
210
9
5
9 & 10
5&6
* Main burners numbered left to right as viewed from
front of boiler.
27
Important Product Safety Information
Refractory Ceramic Fiber Product
Warning:
The Repair Parts list designates parts that contain refractory ceramic fibers
(RCF). RCF has been classified as a possible human carcinogen. When
exposed to temperatures about 1805°F, such as during direct flame contact,
RCF changes into crystalline silica, a known carcinogen. When disturbed as a
result of servicing or repair, these substances become airborne and, if inhaled,
may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace RCF parts or attempt any service or repair work
involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
•
•
•
•
Take steps to assure adequate ventilation.
Wash all exposed body areas gently with soap and water after contact.
Wash work clothes separately from other laundry and rinse washing
machine after use to avoid contaminating other clothes.
Discard used RCF components by sealing in an airtight plastic bag. RCF
and crystalline silica are not classified as hazardous wastes in the United
States and Canada.
First Aid Procedures:
•
•
•
•
28
If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
If breathing difficulty develops: Leave the area and move to a location
with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.
Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.
V. Repair Parts
Section Assembly and Canopy Group.............................30
Base Assembly...................................................................32
Manifold and Main Burners
1 Inch Main Burners...................................................34
40mm Main Burners...................................................36
Pilot Burner and Gas Valve
Continuous Ignition (Standing Pilot)........................38
Electronic Ignition......................................................40
Jacket Assembly................................................................41
Water Trim........................................................................44
Controls..............................................................................46
Draft Hood and Vent Damper..........................................47
Key
No.
Description
Part No.
Quantity
202 202X 203 204 205 206 207 208 209 210
1. Section Assembly (Intermittent and Continuous Circulation Only)
1
Section Assembly, Complete
617170221
1
617170321
---
617170421
---
617170521
---
617170621
617170721
---
---
---
---
---
---
---
---
---
1
1
---
---
---
---
---
---
---
---
---
1
---
---
---
---
---
---
---
---
---
1
---
---
---
---
---
---
---
---
---
---
1
---
---
---
---
---
---
---
---
---
---
1
---
---
---
617170821
---
---
---
---
---
---
---
1
---
---
617170921
---
---
---
---
---
---
---
---
1
---
617171021
---
---
---
---
---
---
---
---
---
1
617170231
1
---
---
---
---
---
---
---
---
---
617170331
---
1
1
---
---
---
---
---
---
---
617170431
---
---
---
1
---
---
---
---
---
---
617170531
---
---
---
---
1
---
---
---
---
---
617170631
---
---
---
---
---
1
---
---
---
---
617170731
---
---
---
---
---
---
1
---
---
---
617170831
---
---
---
---
---
---
---
1
---
---
617170931
---
---
---
---
---
---
---
---
1
---
617171031
---
---
---
---
---
---
---
---
---
1
1. Section Assembly (Gravity Circulation Only)
1
Section Assembly, Complete
29
Key
Description
No.
Part No.
Quantity
202 202X 203
204
205
206 207 208 209 210
2. Canopy Group
61117022
1
---
---
---
---
---
---
---
---
---
611170300
---
1
---
---
---
---
---
---
---
---
611170302
---
---
1
---
---
---
---
---
---
---
611170402
---
---
---
1
---
---
---
---
---
---
611170502
---
---
---
---
1
---
---
---
---
---
611170602
---
---
---
---
---
1
---
---
---
---
611170702
---
---
---
---
---
---
1
---
---
---
611170802
---
---
---
---
---
---
---
1
---
---
611170902
---
---
---
---
---
---
---
---
1
---
611171002
---
---
---
---
---
---
---
---
---
1
Canopy Assembly 206H
6111706010
---
---
---
---
---
1
---
---
---
---
2B
Carriage Bolt, 1/4-20 x 1"
80860115
2
2
2
2
2
2
2
2
2
2
2C
Flat Washer, 1/4"
80860603
2
2
2
2
2
2
2
2
2
2
2D
Nut, Hex, 1/4-20
80860407
2
2
2
2
2
2
2
2
2
2
2E
Cerafelt Sealing Strip, 1/2" x 1" x 10'
6206001
1
1
1
1
1
1
1
1
1
1
2F
Flue Gas Baffle (*Standing Pilot 1"
Burners Only)
(** LP Standing Pilot 1" Burners Only)
(*** Standing Pilot Models Only)
71106001
1***
---
2**
3**
4**
5**
6**
7*
8*
9*
2A
Canopy Assembly (except for 206H)
Section Assembly and Canopy Group
30
THIS PAGE LEFT INTENTIONALLY BLANK
31
Base Assembly
Key
Description
No.
Boiler
Size
Part No.
Qty.
3
3A
32
Base Tray
Boiler
Size
Part No.
Qty.
3. Base Assembly Continued
3. Base Assembly
Base Assembly
(Complete)
Available for 1 Inch
Burners Only
Key
Description
No.
202
618600291
1
202
718600211
1
202X
618600391
1
202X
718600311
1
203
618600391
1
203
718600311
1
204
618600491
1
204
718600411
1
205
618600591
1
205
718600511
1
206
618600691
1
206
718600611
1
207
618600791
1
207
718600711
1
208
618600891
1
208
718600811
1
209
618600991
1
209
718600911
1
210
618601091
1
210
718601011
1
202
718600291
1
All
720601
2
202X
718600391
1
202
72060025
1
203
718600391
1
202X
72060035
1
204
718600491
1
203
72060035
1
205
718600591
1
204
72060045
1
206
718600691
1
205
72060055
1
207
718600791
1
206
72060065
1
208
718600891
1
207
72060075
1
209
718600991
1
208
72060085
1
210
718601091
1
209
72060095
1
210
72060105
1
3B
3B1
3B2
Base Wrapper
Base End Insulation
Base Rear Insulation
Key
Description
No.
Boiler
Size
Part No.
Qty.
3C
Base Front Panel
Assembly
Burner Tray (1" Main
Burners)
3D
Burner Tray
(40mm Main Burners)
Boiler
Size
Part No.
Qty.
3. Base Assembly Continued
3. Base Assembly Continued
202
Key
Description
No.
618600241
1
3E
Base Leg Assembly
All
6186001
4
3E1
Base Leg
All
71860021
4
3E2
Nylon Glide
All
8186006
4
202
718600261
1
202X
718600361
1
203
718600361
1
204
718600461
1
205
718600561
1
206
718600661
1
207
718600761
1
208
718600861
1
209
718600961
1
210
718601061
1
All
6206002
1
202
thru
206
80860700
20
207
thru
210
80860700
21
202X
618600341
1
203
618600341
1
204
618600441
1
205
618600541
1
206
618600641
1
207
618600741
1
208
618600841
1
209
618600941
1
210
618601041
1
202
718600205
1
202X
718600305
1
203
718600305
1
204
718600405
1
205
718600505
1
206
718600605
1
207
718600705
1
208
718600805
1
209
718600905
1
210
718601005
1
202
718600206
1
202X
71806037
1
203
71806037
1
204
71806047
1
205
71806057
1
206
71806067
1
207
71806077
1
208
718600806
1
209
718600906
1
210
718601006
1
3F
3G
3H
Burner Access Panel
Cerafelt Sealing Strip,
1" x 2" x 10' (Section
Assembly to Base)
Self-Tapping Screw,
1/4" -20 x 1/2"
3J
Self-Tapping Screw,
5/16" -18 x 1-1/4"
All
80860717
4
3K
Flat Washer, 5/16",
USS
All
80860601
4
3L
Hex Lock Nut,
5/16 -18
All
80860464
4
33
Manifold and Main Burners
(1 Inch Main Burners)
34
Key
Description
No.
Part No.
Quantity
202
202X
203
2
2
204 205 206 207 208 209 210
4. Manifold and Main Burners (1 Inch Main Burners Only)
4A
Main Burner
4B
Main Burner with Pilot Bracket
4C
4D
4E
4F
Manifold
Main Burner Orifice
8236099
1
-----
4
6
8
11
13
15
17
See Table Below
82260023
1
---
---
---
---
---
---
---
---
---
82260033
---
1
1
---
---
---
---
---
---
---
82260043
---
---
---
1
---
---
---
---
---
---
82260053
---
---
---
---
1
---
---
---
---
---
82260063
---
---
---
---
---
1
---
---
---
---
82260073
---
---
---
---
---
---
1
---
---
---
82260083
---
---
---
---
---
---
---
1
---
---
82260093
---
---
---
---
---
---
---
---
1
---
82260103
---
---
---
---
---
---
---
---
---
1
-----
See Table Below
Screw, Machine, Slotted Round Head,
#10 -32 x 3/16" (Standing Pilot)
80860800
2
2
2
2
2
2
2
2
2
2
Screw, Machine, Philips Head
w/Captive Lockwasher, #10 -32 x 1/4"
(Electronic Ignition)
80860874
1
1
1
1
1
1
1
1
1
1
Screw, Self Tapping, Philips Pan
Head, 1/4 - 20 x 1/2"
80860700
4
4
4
4
4
4
4
4
4
4
4B. 1 Inch Main Burner with Pilot Bracket, 24-volt Continuous Ignition (Standing Pilot) Natural Gas Only
4B
Main Burner with 70° Q350 Pilot
Bracket and Offset Lancings
8236097
1
1
1
1
1
1
1
---
---
---
Main Burner with 60° Pilot Bracket
8236098
---
---
---
---
---
---
---
1
1
1
4B. 1 Inch Main Burner with Pilot Bracket, 24-volt Continuous Ignition (Standing Pilot) LP Gas Only
4B
Main Burner with 45° Pilot Bracket
8236111
---
---
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4B. 1 Inch Main Burner with Pilot Bracket, Electronic Ignition Only
4B
Main Burner with 60° Pilot Bracket
8236098
1
1
4D. 1 Inch Main Burner Orifices, Natural Gas, Normal Altitude, U.S.A. and Canada
4D
Main Burner Orifice, #47 (White)
822710
2
3
---
---
---
---
12
14
16
18
Main Burner Orifice, #45 (Pink)
822711
---
---
3
5
7
9
---
---
---
---
4D. 1 Inch Main Burner Orifices, LP/Propane, Normal Altitude, U.S.A. and Canada
4D
Main Burner Orifice, 1.25 mm (Purple)
822705
2
---
---
5
7
9
---
---
---
---
Main Burner Orifice, #55 (Green)
822708
---
---
3
---
---
---
---
---
---
---
Main Burner Orifice, 3/64" (Blue)
822704
---
3
---
---
---
---
12
14
16
18
35
Manifold and Main Burners
(40mm Main Burners)
Key
No.
Description
Part No.
Quantity
202X 203 204 205 206
207 208 209 210
4. 40 MM Main Burners Only
4A
Main Burner
8236135
1
1
2
3
4
5
6
7
8
4B. 40 MM Main Burner, Electronic Ignition Only
4B
Main Burner with 48° Pilot Bracket
8236143
---
---
---
---
---
---
---
---
---
Main Burner with 41° Pilot Bracket
8236136
1
1
1
1
1
1
1
1
1
4B. 40 MM Main Burner, 24-volt Continuous Ignition (Standing Pilot) Natural Gas Only
4B
Main Burner with 48° Pilot Bracket
8236143
1
1
1
1
1
1
1
1
1
Main Burner with 41° Pilot Bracket
8236136
---
---
---
---
---
---
---
---
---
4B. 40 MM Main Burner, 24-volt Continuous Ignition (Standing Pilot) LP Gas Only
4B
36
Main Burner with 48° Pilot Bracket
8236143
1
---
---
---
---
---
---
---
---
Main Burner with 41° Pilot Bracket
8236136
---
1
1
1
1
1
1
1
1
Key
No.
Description
Part No.
Quantity
202X 203 204 205 206
207 208 209 210
4. 40 MM Main Burners Only (Continued)
4C. 40MM Main Burner Manifold
4C
Manifold
82260028
---
---
---
---
---
---
---
---
---
82260038
1
1
---
---
---
---
---
---
---
82260048
---
---
1
---
---
---
---
---
---
82260058
---
---
---
1
---
---
---
---
---
82260068
---
---
---
---
1
---
---
---
---
82260078
---
---
---
---
---
1
---
---
---
82260088
---
---
---
---
---
---
1
---
---
82260098
---
---
---
---
---
---
---
1
---
82260108
---
---
---
---
---
---
---
---
1
4D. 40 MM Main Burner Orifices Natural Gas, 2001-5000 Ft. USA Only
4D
#43
822713
2
---
---
---
---
---
---
---
---
#39
822727
---
2
3
---
---
---
---
---
---
#38
822720
---
---
---
4
5
6
7
8
9
4D. 40 MM Main Burner Orifices, LP Gas, 2001-5000 Ft. USA Only
4D
#54
822734
2
---
---
---
---
---
---
---
---
#53
822722
---
2
3
4
5
6
7
8
9
4D. 40 MM Main Burner Orifices, Natural Gas, 5001-9000 Ft. USA Only
4D
#41
822729
N/A
2
3
---
---
---
---
---
---
#40
822728
---
---
---
4
5
6
7
8
9
4D. 40 MM Main Burner Orifices, LP Gas, 5001-9000 Ft. USA Only
4D
#54
822734
N/A
2
---
---
---
---
---
---
---
#53
822722
---
---
3
4
5
6
7
8
9
4D. 40 MM Main Burner Orifices, Natural Gas, 2001-4500 Ft. Canada Only
4D
#37
822719
N/A
2
3
4
---
---
---
---
---
#36
822771
---
---
---
---
5
6
7
8
9
4D. 40 MM Main Burner Orifices, LP Gas, 2001-4500 Ft. Canada Only
4D
822721
N/A
2
3
4
5
6
7
8
9
Screw, Machine, Slotted Round Head,
#10-32 x 3/16" (Standing Pilot)
80860800
2
2
2
2
2
2
2
2
2
Screw, Machine, Philips Head
w/Captive Lockwasher, #10-32 x 1/4"
(Electronic Ignition)
80860874
1
1
1
1
1
1
1
1
1
4F
Screw, Self Tapping, Philips Pan Head,
1/4 -20 x 1/2"
80860700
4
4
4
4
4
4
4
4
4
4G
Injection Shield Assembly
71860_ _62
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
4E
#52
_ _: number of cast iron sections
37
* 1" Burner Only
** 40mm Burner Only
Key
Description
No.
Part No.
Quantity
202 202X 203 204 205 206 207 208 209 210
5. Pilot Burner and Gas Valve, 24-volt Continuous Ignition, Natural Gas (1 Inch and 40mm Main Burners)
5A
5B
5C
5D
5E
5F
38
Pilot Burner, Honeywell Q350A1321
8236065
1
1
1
1
1
1
*1
Pilot Burner, Honeywell Q327A1006
8236022
---
---
---
---
---
---
**1
1
1
1
1
1
1
1
1
---
---
---
---
Pilot Orifice, Honeywell 388146AG .026"
Included
with 5A
1
---
---
---
---
---
---
1
1
1
1
Adptr, 1/4"OD x 1/4" NPT Included w/5A & 5E
8236109
2
2
2
2
2
2
2
2
2
2
Pilot Tubing, 1/4" OD x 30" LG
8236122
1
1
1
1
1
1
1
---
---
---
Pilot Tubing, 1/4" OD x 40" LG
8236123
---
---
---
---
---
---
---
1
1
1
Gas Valve, Honeywell VR8200C3005
81660143
1*
1*
1*
1*
1*
1*
---
---
---
---
Gas Valve, Honeywell VR8300C4027
81660154
---
---
---
---
---
---
1*
1*
1*
1*
Gas Valve, Honeywell VR8200C6065
100333-01
1**
1**
1**
1**
1**
1**
---
---
---
---
Gas Valve, Honeywell VR8300C4266
100334-01
---
---
---
---
---
---
1**
1**
1**
1**
Thermocouple, 30", Honeywell Q309A
8236024
1
1
1
1
1
1
1
1
1
1
Pilot Orifice, Honeywell 390686-22 .012"
---
---
---
Key
Description
No.
Part No.
Quantity
202 202X 203 204 205 206 207 208 209 210
5. Pilot Burner and Gas Valve, 24-volt Continuous Ignition, LP/Propane (1 Inch and 40mm Main Burners)
5A
5B
5C
5D
5E
5F
Pilot Burner, Honeywell Q327A1147
8236023
---
---
1
1
1
1
1
1
1
1
Pilot Burner Assembly, Honeywell Q350A
(Includes 5B & 5F)
8236105
1
1
---
---
---
---
---
---
---
---
---
---
1
1
1
1
1
1
1
1
Pilot Orifice, Honeywell 390686-23 (.008")
Included
with 5A
1
1
---
---
---
---
---
---
---
---
Adptr, 1/4"OD x 1/4" NPT Included w/5A & 5E
8236109
2
2
2
2
2
2
2
2
2
2
Pilot Tubing, 1/4" OD x 30" LG
8236122
1
1
1
1
1
1
1
---
---
---
Pilot Tubing, 1/4" OD x 40" LG
8236123
---
---
---
---
---
---
---
1
1
1
Gas Valve, Honeywell VR8200C3013
81660144
1
1
1
1
1
1
---
---
---
---
Gas Valve, Honeywell VR8300C4035
81660163
---
---
---
---
---
---
1
1
1
1
Thermocouple, 30", Honeywell Q309A
8236024
1
1
1
1
1
1
1
1
1
1
Pilot Orifice, Honeywell 388146KR (.014")
39
Key
No.
Description
Part No.
Quantity
202 202X 203 204 205 206 207 208 209 210
5. Pilot Burner and Gas Valve, Electronic Ignition (EI), Natural Gas
5A
Pilot Burner, Honeywell Q348A1002
8236072
1
1
1
1
1
1
1
1
1
1
5B
Pilot Orifice, Honeywell 388146NE
Included
with 5A
1
1
1
1
1
1
1
1
1
1
5C
Compression Nut/Fitting, 1/4" OD x 1/4 C.C.
(Included with 5A and 5E)
8236109
2
2
2
2
2
2
2
2
2
2
Pilot Tubing, 1/4" OD x 30"
8236122
1
1
1
1
1
1
1
---
---
---
Pilot Tubing, 1/4" OD x 40"
8236123
---
---
---
---
---
---
---
1
1
1
Gas Valve, Honeywell VR8204C3007
81660145
1
1
1
1
1
1
---
---
---
---
Gas Valve, Honeywell VR8304P4306
81660161
---
---
---
---
---
---
1
1
1
1
5F
Igniter/Sensor Cable, 36", Honeywell 394800
8236084
1
1
1
1
1
1
1
1
1
1
5G
Ground Wire Assembly
6136054
1
1
1
1
1
1
1
1
1
1
5D
5E
5. Pilot Burner and Gas Valve, Electronic Ignition (EI), LP/Propane
5A
Pilot Burner, Honeywell Q348A1010
8236081
1
1
1
1
1
1
1
1
1
1
5B
Pilot Orifice, Honeywell 388146KP
Included
with 5A
1
1
1
1
1
1
1
1
1
1
5C
Compression Nut/Fitting, 1/4" OD x 1/4 C.C.
(Included with 5A and 5E)
8236109
2
2
2
2
2
2
2
2
2
2
Pilot Tubing, 1/4" OD x 30"
8236122
1
1
1
1
1
1
1
---
---
---
Pilot Tubing, 1/4" OD x 40"
8236123
---
---
---
---
---
---
---
1
1
1
Gas Valve, Honeywell VR8204C3015
81660146
1
1
1
1
1
1
---
---
---
---
Gas Valve, Honeywell VR8304P4314
81660160
---
---
---
---
---
---
1
1
1
1
5F
Igniter/Sensor Cable, 36", Honeywell 394800
8236084
1
1
1
1
1
1
1
1
1
1
5G
Ground Wire Assembly
6136054
1
1
1
1
1
1
1
1
1
1
5D
5E
40
Key
No.
Description
Part No.
Quantity
202 202X 203 204 205 206 207 208 209 210
6. Jacket Assembly, Complete
6
Jacket Assembly, Complete
604170254
1
---
---
---
---
---
---
---
---
---
604170354
---
1
1
---
---
---
---
---
---
---
604170454
---
---
---
1
---
---
---
---
---
---
604170554
---
---
---
---
1
---
---
---
---
---
604170654
---
---
---
---
---
1
---
---
---
---
604170754
---
---
---
---
---
---
1
---
---
---
604170854
---
---
---
---
---
---
---
1
---
---
604170954
---
---
---
---
---
---
---
---
1
---
604171054
---
---
---
---
---
---
---
---
---
1
604170215
1
---
---
---
---
---
---
---
---
---
604170315
---
1
1
---
---
---
---
---
---
---
604170415
---
---
---
1
---
---
---
---
---
---
604170515
---
---
---
---
1
---
---
---
---
---
604170615
---
---
---
---
---
1
---
---
---
---
604170715
---
---
---
---
---
---
1
---
---
---
604170815
---
---
---
---
---
---
---
1
---
---
604170915
---
---
---
---
---
---
---
---
1
---
604171015
---
---
---
---
---
---
---
---
---
1
6. Jacket Assembly
6A
Jacket Wrap-Around Panel
41
42
Key
No.
Description
Part No.
Quantity
202 202X 203 204 205 206 207 208 209 210
6. Jacket Assembly (Continued)
6B
6C
6D
6E
Jacket Vestibule Panel
Jacket Top Panel
Jacket Front Removable Door
Jacket Lower Front Panel
604170223
1
---
---
---
---
---
---
---
---
---
604170323
---
1
1
---
---
---
---
---
---
---
604170423
---
---
---
1
---
---
---
---
---
---
604170523
---
---
---
---
1
---
---
---
---
---
604170623
---
---
---
---
---
1
---
---
---
---
604170723
---
---
---
---
---
---
1
---
---
---
604170823
---
---
---
---
---
---
---
1
---
---
604170923
---
---
---
---
---
---
---
---
1
---
604171023
---
---
---
---
---
---
---
---
---
1
604170233
1
---
---
---
---
---
---
---
---
---
604170333
---
1
1
---
---
---
---
---
---
---
604170433
---
---
---
1
---
---
---
---
---
---
604170533
---
---
---
---
1
---
---
---
---
---
604170633
---
---
---
---
---
1
---
---
---
---
604170733
---
---
---
---
---
---
1
---
---
---
604170833
---
---
---
---
---
---
---
1
---
---
604170933
---
---
---
---
---
---
---
---
1
---
604171033
---
---
---
---
---
---
---
---
---
1
604170242
1
---
---
---
---
---
---
---
---
---
604170342
---
1
1
---
---
---
---
---
---
---
604170442
---
---
---
1
---
---
---
---
---
---
604170542
---
---
---
---
1
---
---
---
---
---
604170642
---
---
---
---
---
1
---
---
---
---
604170742
---
---
---
---
---
---
1
---
---
---
604170842
---
---
---
---
---
---
---
1
---
---
604170942
---
---
---
---
---
---
---
---
1
---
604171042
---
---
---
---
---
---
---
---
---
1
604170216
1
---
---
---
---
---
---
---
---
---
604170316
---
1
1
---
---
---
---
---
---
---
604170416
---
---
---
1
---
---
---
---
---
---
604170516
---
---
---
---
1
---
---
---
---
---
604170616
---
---
---
---
---
1
---
---
---
---
604170716
---
---
---
---
---
---
1
---
---
---
604170816
---
---
---
---
---
---
---
1
---
---
604170916
---
---
---
---
---
---
---
---
1
---
604171016
---
---
---
---
---
---
---
---
---
1
6F
Sheet Metal Screw, Type AB, Phillips
Truss Head, #8 x 1/2"
80860000
26
26
26
26
26
26
26
26
26
26
6G
Snap Bushing, Heyco SB-1093-15
8136257
2
2
2
2
2
2
2
2
2
2
6H
Snap Bushing, Heyco SB-437-5
8136048
1
1
1
1
1
1
1
1
1
1
43
Water Trim
44
Key
No.
7
Description
Part No.
Quantity
Safety Relief Valve, 30 psi, 3/4 NPT, Conbraco 10-408-05
81660319
1
Safety Relief Valve, 50 psi, 3/4 NPT, Conbraco 10-303-10
101662-01
1
8. Circulator, Bell & Gossett SLC-30 Option (Intermittent and Continuous Circulation Only)
8A
Circulator with Gaskets, Bell & Gossett NRF-22
8B
Gasket, Bell & Gossett NRF-22
8056174
1
806602029
2
8. Circulator, Grundfos Option (Intermittent and Continuous Circulation Only)
8A
Circulator with Gaskets, Grundfos UP 15-42F
8B
Gasket, Grundfos 510179
8056173
1
806602016
2
8. Circulator, Taco 007 Option (Intermittent and Continuous Circulation Only)
8A
Circulator with Gaskets, Taco 007F
8B
Gasket, Taco '00' Series
8056170
1
806602006
2
8. Circulator, Taco 0010 Option (Intermittent and Continuous Circulation Only)
8A
Circulator with Gaskets, Taco 0010
8B
Gasket, Taco '00' Series
8056176
1
806602006
2
9. Miscellaneous Circulator Hardware (Intermittent and Continuous Circulation Only)
9A
Flange, 1-1/4 NPT
806602013
2
9B
Screw, Cap Hex Head, 7/16 -14 x 1-1/2"
80861301
4
9C
Nut, Hex, 7/16 -14
80860406
4
100189-01
1
----
1
10. Limit Control
10A
Limit, Honeywell L4080D1234
10B
Well, 1/2 NPT (Included w/10A)
10C
Limit, Honeywell L4080B1212 (Dual Limit Only)
80160474
1
10D
Well, 3/4 NPT, Honeywell 123870A (Dual Limit Only)
80160426
1
11. Miscellaneous Trim
11A
Drain Valve, Conbraco 35-302-03
806603061
1
11B
Temperature - Pressure Gauge
100282-01
1
11C
Nipple, 1-1/4 NPT x 3"
806600005
1 or 2
11D
Tee, 1-1/4 x 3/4 x 1-1/4 NPT
806601002
1 or 2
11E
Nipple, 1-1/4 NPT x 4"
806600028
1
45
Key
No.
Description
Part No.
Quantity
8136259
1
12. Transformer/Relay Assembly (Intermittent Circulation Only)
12A
Junction Box, 4" x 4" x 1-1/2"
12B
Transformer/Relay, Honeywell R8285D5001
80160155U
1
12C
Relay, Honeywell R8222U1006
80160096U
1
12. Transformer (Continuous and Gravity Circulation Only)
12A
Junction Box, 4" x 4" x 1-1/2"
8136259
1
12D
Transformer, 40VA, Honeywell AT140D1012 or AT72D1188
80160039
1
13. Flame Rollout Switch
13A
Flame Rollout Switch
80160044
1
13B
Flame Rollout Switch Mounting Bracket
7186018
1
6016058
1
100958-01
1
7016001
1
14. Blocked Vent Switch
14
Blocked Vent Switch Replacement Assembly
15. Ignition Module (EI Only)
15A
Ignition Module, Honeywell S8610M3009
15B
Ignition Module Support Bracket
46
Key
No.
Description
Part No.
Quantity
202 202X 203 204 205 206 207 208 209 210
16. Draft Hood Carton
16
8116067
1
1
1
---
---
---
---
---
---
---
8111702
---
---
---
1
---
---
---
---
---
---
8111703
---
---
---
---
1
1
---
---
---
---
8111704
---
---
---
---
---
---
1
1
---
---
8111705
---
---
---
---
---
---
---
---
1
1
4"
8116321
1
1
1
---
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5"
8116322
---
---
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1
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6"
8116323
---
---
---
---
1
1
---
---
---
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7"
8116324
---
---
---
---
---
---
1
1
---
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8"
8116325
---
---
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---
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1
1
1
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Draft Hood
17. Vent Damper
17
18. Vent Reducer
18
Reducer, 4" x 3"
47
SERVICE RECORD
DATE
48
SERVICE PERFORMED
SERVICE RECORD
DATE
SERVICE PERFORMED
49
SERVICE RECORD
DATE
50
SERVICE PERFORMED
VI. Low Water Cut Off (LWCO)
WARNING
DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use
connections specifically identified for Low Water Cut Off.
In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions.
When
A low water cutoff is required to protect a hot water
boiler when any connected heat distributor (radiation) is
installed below the top of the hot water boiler (i.e.
baseboard on the same floor level as the boiler). In
addition, some jurisdictions require the use of a LWCO
with a hot water boiler.
Where
The universal location for a LWCO on both gas and oil
hot water boilers is above the boiler, in either the supply
or return piping. The minimum safe water level of a
water boiler is at the uppermost top of the boiler; that is,
it must be full of water to operate safely.
manufacturers recommend an annual inspection of the
probe.
How to Wire
What Kind
Typically, in residential applications, a probe type
LWCO is used instead of a float type, due to their
relative costs and the simplicity of piping for a probe
LWCO.
LWCO’s are available in either 120 VAC or 24 VAC
configurations. The 120 VAC configuration can be
universally applied to both gas and oil boilers by wiring
it in the line voltage service to the boiler (after the
service switch, if so equipped).
The presence of water in a properly installed LWCO
will cause the normally open contact of the LWCO to
close, thus providing continuity of the 120 VAC service
to the boiler.
It is recommended to supply power to the probe LWCO
with the same line voltage boiler service as shown
below.
How to Pipe
A “tee” is commonly used to connect the probe LWCO
to the supply or return piping, as shown below.
LWCO Location
Select the appropriate size tee using the LWCO
manufacturer’s instructions. Often, the branch
connection must have a minimum diameter to
prevent bridging between the probe and the tee. Also,
the run of the tee must have a minimum diameter to
prevent the end of the probe from touching or being
located too close to the inside wall of the run of the tee.
Ideally, manual shutoff valves should be located above
the LWCO and the boiler to allow for servicing. This
will allow probe removal for inspection without
draining the heating system. Many probe LWCO
Wiring of Typical LWCO
A 24 VAC LWCO is used primarily for gas fired boilers
where a 24 volt control circuit exists within the boiler.
However, a 24 VAC LWCO can only be used if the
boiler manufacturer has provided piping and wiring
connections and instructions to allow for this
application.
How to Test
Shut off fuel supply. Lower water level until water
level is BELOW the LWCO. Generate a boiler demand
by turning up thermostat. Boiler should not attempt to
operate. Increase the water level by filling the system.
The boiler should attempt to operate once the water
level is above the LWCO.
51
U.S. Boiler Company, Inc.
P.O. Box 3020
Lancaster, PA 17604
(717) 397-4701
www.usboiler.burnham.com
52